All qualifications and part qualifications registered on the National Qualifications Framework are public property. Thus the only payment that can be made for them is for service and reproduction. It is illegal to sell this material for profit. If the material is reproduced or quoted, the South African Qualifications Authority (SAQA) should be acknowledged as the source.

SOUTH AFRICAN QUALIFICATIONS AUTHORITY

REGISTERED UNIT STANDARD:

Demonstrate an understanding of cement technology

SAQA US ID

UNIT STANDARD TITLE

10462

Demonstrate an understanding of cement technology

ORIGINATOR

SGB Mining and Minerals

PRIMARY OR DELEGATED QUALITY ASSURANCE FUNCTIONARY

-

FIELD

SUBFIELD

Field 06 - Manufacturing, Engineering and Technology

Fabrication and Extraction

ABET BAND

UNIT STANDARD TYPE

PRE-2009 NQF LEVEL

NQF LEVEL

CREDITS

Undefined

Regular

Level 4

NQF Level 04

22

REGISTRATION STATUS

REGISTRATION START DATE

REGISTRATION END DATE

SAQA DECISION NUMBER

Reregistered

2018-07-01

2023-06-30

SAQA 06120/18

LAST DATE FOR ENROLMENT

LAST DATE FOR ACHIEVEMENT

2024-06-30

2027-06-30

In all of the tables in this document, both the pre-2009 NQF Level and the NQF Level is shown. In the text (purpose statements, qualification rules, etc), any references to NQF Levels are to the pre-2009 levels unless specifically stated otherwise.

This unit standard does not replace any other unit standard and is not replaced by any other unit standard.

PURPOSE OF THE UNIT STANDARD

This unit standard will be useful for people who are working in the cement industry in South Africa and who require an in-depth understanding of cement technology.

People credited with this unit standard are able to demonstrate an in-depth understanding of

Raw materials used in cement manufacture;

Manufacturing processes;

Refractories and their use and applications;

Cementation process and

Applications of the product

LEARNING ASSUMED TO BE IN PLACE AND RECOGNITION OF PRIOR LEARNING

The credit calculation is based on the assumption that learners are already competent in terms of the following outcomes or areas of learning when starting to learn towards this unit standard:

Mathematical literacy at NQF Level 3

Communications at NQF level 3

Science at NQF level 3

Chemistry at NQF level 3

UNIT STANDARD RANGE

Specific range statements are provided in the body of the unit standard where they apply to particular specific outcomes or assessment criteria.

Specific Outcomes and Assessment Criteria:

SPECIFIC OUTCOME 1

Indicate the nature and sources of raw materials and their combinations to produce.

OUTCOME NOTES

Indicate the nature and sources of raw materials and their combinations to produce an economically viable cement clinker.

ASSESSMENT CRITERIA

ASSESSMENT CRITERION 1

1. The various raw materials used in the cement clinker manufacturing process are described in terms of their contribution to the product.

ASSESSMENT CRITERION RANGE

Calcareous minerals

Alumina rich minerals

Siliceous minerals

Iron rich minerals

ASSESSMENT CRITERION 2

2. The effect of deleterious contaminants in the raw materials is explained in terms of the process and the product.

ASSESSMENT CRITERION RANGE

Magnesium

Halogens

Heavy metals

Sulphur

Phosphorus

Alkalis

ASSESSMENT CRITERION 3

3. The sources of raw materials and their geographical locations are identified.

ASSESSMENT CRITERION 4

4. The critical elements and the proportions required for an acceptable mix design to produce clinker are explained.

ASSESSMENT CRITERION 5

5. The selection of raw materials is described in terms of cost, transport and handling issues.

SPECIFIC OUTCOME 2

The preparation and chemical conversion of raw materials to cement clinker is explained in terms.

OUTCOME NOTES

The preparation and chemical conversion of raw materials to cement clinker is explained in terms of the processes and mineralogy.

ASSESSMENT CRITERIA

ASSESSMENT CRITERION 1

1. The purpose of blending, drying, milling and homogenising the raw materials is explained.

ASSESSMENT CRITERION RANGE

Raw meal quality (fineness)

Moisture content

Consistency of kiln feed

ASSESSMENT CRITERION 2

2. The combustion process is explained in terms of cement clinker production.

ASSESSMENT CRITERION RANGE

Fuel types

Preparation of the fuel

Effect of coal ash

Calorific value, volatiles and ash content

Fuel/air ratios

Exhaust gas condition

Kiln temperature profile

ASSESSMENT CRITERION 3

3. The transformation of kiln feed into cement clinker is described in relation to the various zones of the kiln.

ASSESSMENT CRITERION RANGE

Preheating

Calcining

Inlet transition

Burning zone

Outlet transition

Cooling

ASSESSMENT CRITERION 4

4. The principal mineral components and quality parameters of the cement clinker are listed.

ASSESSMENT CRITERION RANGE

C2S; C3S; C3A; C4AF

Lime Saturation Factors

Loss On Ignition

Free Lime

Clinker Moduli (alumina, iron, silica)

SPECIFIC OUTCOME 3

Describe the milling process whereby clinker is converted to to cement.

ASSESSMENT CRITERIA

ASSESSMENT CRITERION 1

1. The feed materials are named and their proportional relationships are explained.

ASSESSMENT CRITERION RANGE

Clinker

Gypsum

Limestone

Extenders

Grinding aids

Strength enhancers

ASSESSMENT CRITERION 2

2. The finish milling process is explained.

ASSESSMENT CRITERION RANGE

Comminution

Energy consumption

Quality parameters

SPECIFIC OUTCOME 4

Demonstrate knowledge of various kiln refractory materials and their purpose.

ASSESSMENT CRITERIA

ASSESSMENT CRITERION 1

1. The refractories are listed by type and application per zone.

ASSESSMENT CRITERION RANGE

Shapes/monolithics

Basic/acid/spinel

ASSESSMENT CRITERION 2

2. The functions of refractories are explained in terms of their application in the cement manufacturing process.

SPECIFIC OUTCOME 5

Explain the cementation process and the common field applications of cement.

ASSESSMENT CRITERIA

ASSESSMENT CRITERION 1

1. The hydration process of cement is described.

ASSESSMENT CRITERION RANGE

Cement/water ratio

Setting time and control

Workability

Strength development

Heat of hydration

ASSESSMENT CRITERION 2

2. Deleterious contaminants and their effects are listed.

ASSESSMENT CRITERION RANGE

Active carbon, i.e. sugar, organic matter

Extreme retardation or failure to set and gain strength

ASSESSMENT CRITERION 3

3. The principal applications of cement are described.

ASSESSMENT CRITERION RANGE

Concrete

Concrete products

Plaster and mortar

Soil stabilisation

UNIT STANDARD ACCREDITATION AND MODERATION OPTIONS

1. Anyone assessing a learner against this unit standard must be registered as an assessor with the relevant ETQA.

2. Any institution offering learning that will enable achievement of this unit standard must be accredited as a provider through the relevant ETQA by SAQA.

3. Moderation of assessment will be overseen by the relevant ETQA according to the moderation guidelines and the agreed ETQA procedures.

UNIT STANDARD ESSENTIAL EMBEDDED KNOWLEDGE

Essential embedded knowledge will be assessed through assessment of the specific outcomes in terms of the stipulated assessment criteria. Without knowledge of the listed embedded knowledge, candidates are unlikely to achieve all the specific outcomes to the standards described in the assessment criteria. This means that for the most part, the possession or lack of the knowledge can be directly inferred from the quality of the candidate`s performance. Where direct assessment of knowledge is required, assessment criteria have been included in the body of the unit standard.

UNIT STANDARD DEVELOPMENTAL OUTCOME

N/A

UNIT STANDARD LINKAGES

N/A

Critical Cross-field Outcomes (CCFO):

UNIT STANDARD CCFO IDENTIFYING

Identify and solve problems and make decisions using critical and creative thinking.

Note: The ability of the candidate to identify substandard and hazardous conditions, assess and take appropriate action.

UNIT STANDARD CCFO WORKING

Work effectively with others as a member of a team, group, organisation or community.

Note: The ability and willingness of the candidate to accept and interpret work instructions correctly.

UNIT STANDARD CCFO ORGANISING

Organise and manage himself / herself and his / her activities responsibly and effectively.

Note: The ability of the candidate to indicate what methods, tools and personal protective equipment are required, and to communicate to fellow workers his / her intentions and the assistance required.

UNIT STANDARD CCFO COLLECTING

Collect, analyse, organise and critically evaluate information.

Note: The ability of the candidate to reconcile the information from visual and physical examinations and constantly evaluate the changing situation.

UNIT STANDARD CCFO COMMUNICATING

Communicate effectively, using visual, mathematical and / or language skills in the modes of oral and / or written presentations.

Note: The appropriate communication with the relevant personnel with regard to the reporting of hazards and substandard conditions will indicate his / her proficiency in effective communication.

UNIT STANDARD CCFO SCIENCE

Use science and technology effectively and critically, thus showing responsibility towards the environment and health of others.

Note: The use of science and technology is not relevant for this unit standard.

UNIT STANDARD CCFO DEMONSTRATING

Demonstrate an understanding of the world as a set of related systems by recognising that problem-solving contexts do not exist in isolation.

Note: The ability of the candidate to identify and refer anomalous behaviour to a specialist confirms his / her understanding of the fact that a specific observation, inference, action or decision may have a devastating effect.

UNIT STANDARD ASSESSOR CRITERIA

Assessors should keep the following principles in mind when designing and conducting assessments against this unit standard:

Focus the assessment activities on gathering evidence in terms of the main outcome expressed in the title to ensure assessment is integrated rather than fragmented. Remember, we want to declare the person competent in terms of the title. Where assessment at title level is unmanageable, then focus assessment around each specific outcome, or groups of specific outcomes.

Make sure evidence is gathered across the entire range, wherever it applies. Assessment activities should be as close to the real performance as possible, and where simulations or role-plays are used, there should be supporting evidence to show the candidate is able to perform in the real situation.

Do not focus the assessment activities on each assessment criterion. Rather make sure the assessment activities focus on outcomes and are sufficient to enable evidence to be gathered around all the assessment criteria.

The assessment criteria provide the specifications against which assessment judgements should be made. In most cases, knowledge can be inferred from the quality of the performances, but in other cases, knowledge and understanding will have to be tested through questioning techniques. Where this is required, there will be assessment criteria to specify the standard required.

The task of the assessor is to gather sufficient evidence - of the prescribed type and quality as specified in this unit standard - that the candidate can achieve the outcomes again and again and again. This means assessors will have to judge how many repeat performances are required before they believe the performance is reproducible.

All assessments should be conducted in line with the following well-documented principles of assessment, namely appropriateness, fairness, manageability, integration into work or learning, validity, direct, authentic, sufficient, systematic, open and consistent.

REREGISTRATION HISTORY

As per the SAQA Board decision/s at that time, this unit standard was Reregistered in 2012; 2015.

UNIT STANDARD NOTES

Terminology

Specified requirements include legal and site-specific requirements and are contained in one or more of the following documents:

This information shows the current accreditations (i.e. those not past their accreditation end dates), and is the most complete record available to SAQA as of today. Some Primary or Delegated Quality Assurance Functionaries have a lag in their recording systems for provider accreditation, in turn leading to a lag in notifying SAQA of all the providers that they have accredited to offer qualifications and unit standards, as well as any extensions to accreditation end dates. The relevant Primary or Delegated Quality Assurance Functionary should be notified if a record appears to be missing from here.

1.

NKOMATI MINE

2.

PRETORIA PORTLAND CEMENT CO_LTD (HEAD OFFICE)

3.

XTRACT TRAINING SERVICES (PTY) LTD

All qualifications and part qualifications registered on the National Qualifications Framework are public property. Thus the only payment that can be made for them is for service and reproduction. It is illegal to sell this material for profit. If the material is reproduced or quoted, the South African Qualifications Authority (SAQA) should be acknowledged as the source.